Atlas Copco

ROC DMK-II TH (with Bosal cabin)

System description

© Copyright 2007, Atlas Copco Rock Drills AB, Sweden Any unauthorized use or copying of
the contents or any part thereof is prohibited. This applies in particular to trademarks, model
denominations, part numbers and drawings

ROC DMK-II TH (with Bosal cabin) system description, PMI NR: 9853 1129 01
 Introduction

Introduction

Abbreviations

RAS Rod Adding System

RCS Rig Control System
RHS Rod Handling System
ECM Engine Control Module
EMS Engine Monitoring System
CCU CAN Control Unit
DPCI Damper Pressure Controlled Impact
RPCF Rotation Pressure Controlled Feed
ECL Electrically Controlled Lubrication
ECG Electrically Controlled Greasing
DCT Dust Collector
DTH Down The Hole
TH Top Hammer
CR COPROD
PWM Pulse With Modulation
PTO Power Take Out

Signal types
Digital input – 24 V input signal
Digital output – 24 V output signal

Data protocol types

Can Bus – Data protocol between remote control box and the CAN control unit

1
 Contents

Contents
INTRODUCTION...................................................................................................................................................1
ABBREVIATIONS..............................................................................................................................................1
SIGNAL TYPES..................................................................................................................................................1
DATA PROTOCOL TYPES...............................................................................................................................1
CONTENTS.............................................................................................................................................................2

TECHNICAL DATA..............................................................................................................................................4

HYDRAULIC SYSTEM, GENERAL...................................................................................................................6

GENERAL......................................................................................................................................................................................................6
PILOT PRESSURE..............................................................................................................................................6
RETURN OIL AND OIL COOLER....................................................................................................................7
TEST CONNECTIONS FOR THE HYDRAULIC CIRCUITS..........................................................................8
ELECTRICAL SYSTEM, GENERAL.................................................................................................................9
GENERAL......................................................................................................................................................................................................9
BATTERY AND CHARGING............................................................................................................................9
MAIN FUSE........................................................................................................................................................9
ELECTRIC CABINET.........................................................................................................................................9
PLC.....................................................................................................................................................................11
DIESEL ENGINE.................................................................................................................................................12
BATTERY SWITCH, OFF..........................................................................................................................................................................12
BATTERY SWITCH, ON...........................................................................................................................................................................12
IGNITION POSITION.......................................................................................................................................12
START POSITION............................................................................................................................................13
CONTROL INSTRUMENTATION..................................................................................................................13
FAULT INDICATORS......................................................................................................................................14
ENGINE SPEED................................................................................................................................................15
COMPRESSOR.....................................................................................................................................................16
COMPRESSOR UNIT.......................................................................................................................................16
AIR FLOW...................................................................................................................................................................................................16
COOLING AND OIL SYSTEMS......................................................................................................................17
REGULATOR SYSTEM...................................................................................................................................17
INSTRUMENT AND FAULT INDICATION..................................................................................................17
PUMPS AND PILOT PRESSURE......................................................................................................................18
PUMP 1................................................................................................................................................................18
INTERNAL PRESSURE VALVE.....................................................................................................................18
EXTERNAL PRESSURE VALVE...................................................................................................................18
PUMP 1, PRESSURE SETTING................................................................................................................................................................18
PILOT PRESSURE............................................................................................................................................19
TRAMMING.........................................................................................................................................................20
CONDITIONS..............................................................................................................................................................................................20
TRAMMING WARNING.................................................................................................................................22
HYDRAULIC JACK.........................................................................................................................................22
POSITIONING......................................................................................................................................................23
BOOM AND FEED POSITIONING.................................................................................................................23
TRACK OSCILLATION...................................................................................................................................24
OIL PRE-HEATING............................................................................................................................................25
 Contents
DRILLING.............................................................................................................................................................26

Content
AIR FLUSHING...........................................................................................................................................................................................
s 27
ROTATION..................................................................................................................................................................................................28
DRILL FEED................................................................................................................................................................................................30
PERCUSSION..............................................................................................................................................................................................32
RAPID FEED...............................................................................................................................................................................................34
THREADING...............................................................................................................................................................................................36
DAMPER AND DPC-I SYSTEM........................................................................................................................38
ADJUSTING DAMPER PRESSURE...............................................................................................................38
DPC-I SYSTEM.........................................................................................................................................................................................38
LOGIC BLOCK 1...................................................................................................................................................42
LOGIC BLOCK 2...................................................................................................................................................42
LOGIC BLOCK 3...................................................................................................................................................42
PROTECTIVE PROTECTIONS.........................................................................................................................43
ANTI-JAMMING........................................................................................................................................................................................43
RPCF..................................................................................................................................................................44
AIR SYSTEM........................................................................................................................................................45
AIR SYSTEM...............................................................................................................................................................................................45
ECL, ROCK DRILL LUBRICATION SYSTEM..............................................................................................45
ECG, THREAD LUBRICATION...............................................................................................................................................................45
DCT, DUST COLLECTOR........................................................................................................................................................................46
HQS (HOLE QUALITY SYSTEM)....................................................................................................................48

RHS, ROD HANDLING SYSTEM......................................................................................................................49

GENERAL....................................................................................................................................................................................................49
SYSTEM PRESSURE.......................................................................................................................................49
CAROUSEL ROTATION.................................................................................................................................50
RHS ARM...................................................................................................................................................................................................51
GRIPPER CLAWS (ON RHS ARMS).......................................................................................................................51
OPEN GRIPPER CLAWS...........................................................................................................................................................................51
LOOSE GRIP...............................................................................................................................................................................................52
TIGHT GRIP................................................................................................................................................................................................52
DRILL-STEEL SUPPORT AND SUCTION HOOD.........................................................................................54
UPPER DRILL STEEL SUPPORT...................................................................................................................54
LOWER DRILL STEEL SUPPORT.................................................................................................................54
SUCTION HOOD.........................................................................................................................................................................................54
OPTIONS...............................................................................................................................................................55
WATERMIST SYSTEM (OPTION)............................................................................................................................55
WINCH (REMOTE CONTROL BOX, OPTION)..........................................................................................................57
EXTRACTION UNIT (OPTION)...............................................................................................................................60
ECG, THREAD LUBRICATION WITH OIL (OPTION)................................................................................................61
THREAD LUBRICATION WITH GREASE BRUSHES (OPTION)..............................................................61
ADJUSTMENT/CALIBRATION........................................................................................................................63
ADJUSTABLE PARAMETERS, DCT.......................................................................................................................63
ADJUSTABLE DRILLING PARAMETERS...................................................................................................64
SEARCH LIST......................................................................................................................................................65
 Technical data

Technical data
Weight (without drill steels)
ROC D5/D7/D9 Weight 14 500
Kg
Performance
Diesel engine, CAT C7 output at 2200 rpm 168 kW
Temperature range in operation -25° to +50°C
Tramming speed (low/high gear) 1.5/3.1 km/h
Traction force (low/high gear) 115/81 kN
Ground pressure, average 0.091 N/mm2
Ground clearance 455 mm
Max. hydraulic pressure 250 bar
Track oscillation 12°
Noise level (inside cab) Drilling (2000 78.8 dB(A)
rpm)
Noise level (outside cab)
Idling (1500 rpm) 109 dB(A)
Max. engine speed (2200 rpm) 114 dB(A)
Drilling (2000 rpm) 127 dB(A)
Vibration in operator’s seat during drilling
(weighted average) 0.14 m/s2

Gradients D5/D7/D9 -1X

Note
Stability is specified with respect to CE standards stipulating that rigs must not be
operated on inclines steeper than 20 degrees without the use of a winch.
ANGLES MUST NOT BE COMBINED!

Tilt angles for drill rig when drilling:

Longitudinally, max. (Downward/Upward) 20°/20°
lateral (left/right). 17°/13°
laterally, (left/right), in extreme positions. 17°/11°
Tilt angles - tramming (in direction):
downward/upward, max. without winch 20°/20°
laterally, max. (Left/Right) 20°/20°
downward/upward, with winch 30°

Hydraulic system
Hydraulic oil cooler for max. ambient temperature +50°C

Electrical system
Voltage 24 V
Batteries
Voltage 2 * 12 V/185 Ah
Working lights
Voltage 24 V/70 W
Generator
Voltage 28 V/95 Ah
Air system D5
Compressor G
106GD
Max. Air pressure 10.5
bar
Free air delivery at 8.5 bar 82 l/s
Working pressure 10.5
bar
Air system D7
Compressor G
106GD
Max. Air pressure 10.5
bar
Free air delivery at 10.5 bar 105 l/s
Free air delivery at 10.5 bar (USA version) 127 l/s
Working pressure 10.5
bar
Air system D9
Compressor G
106GD
Max. Air pressure 10.5
bar
Free air delivery at 10.5 bar 135 l/s
Working pressure 10.5
bar
Capacities
Hydraulic oil reservoir, min/max level 220/26
0l
Hydraulic system, total 300 l
Fuel tank 370 l
Traction gear 3l
Compressor oil 24 l
Lubrication oil tank 10 l
Diesel engine oil 28 l
Engine cooling system 31 l

Air conditioning
Red Dot
Refrigerant, type R134A
Refrigerant, quantity 2.53 kg

Miscellaneous
Fire extinguisher A-B-C powder 1*6
kg
 Hydraulic system, general

Hydraulic system, general

General
The hydraulic system on the ROC D5/D7/D9 is an electrical and pilot pressure controlled system. The
system comprises 4 hydraulic pumps. Hydraulic pumps 1 and 2 are driven directly by the diesel engine
via a flexible coupling. The remaining pumps (3 and 4) are fitted as a double pump on the engine's
power take off (PTO).

Feed cylinder

Logic Valves Flow divider Tramming

Main Drill block control

DrillRapid Impact Rotation

RPCF
Tramming Pre-heat feedfeed TractionTraction
leftright
Remote
Pressure control box
Control Positioning
Panel & during drilling
Gauges
Rod
handlingDust collector
?
Winch/
Positioning during tramming

Cooler motor

1
2 3 4

Pilot pressure
The pilot pressure is generated in the main drilling block and winch block. This pressure supplies the
drilling block's directional valves with oil. This pilot pressure also supplies the tramming block’s
directional valves with oil and the directional valves for high-speed tramming and winch freewheel.

The pressure control panel controls the working pressure to pump 1, the feed pressure and rotation
speed in the main drilling block.
Return oil and oil cooler
The Hydraulic oil tank has a capacity of 260 litres which means that there is always a “stock” of oil
in the tank. In addition to storage it serves to separate water and dirt. There are two holders with 3
filters in each which filters hydraulic oil from the return- and drain circuit and the oil during filling.
There is also a ventilation filter which prevents contaminated air from entering the tank when the
hydraulic oil level is changed. Thermostats ensure that the oil flows through the oil cooler when the
temperature is above 40ºC and directly to the tank when the temperature is below 40ºC. The by-pass
valve protects the oil cooler from exposing to high pressure.

The oil cooler cools the hydraulic oil so that the rig can work at full load in ambient temperatures up
to 50°C. The cooling fan is driven by a hydraulic motor that is supplied with oil from pump 4 at a
maximum pressure of 160 bars (D5) or 220 bar (D7).

T- Return oil is a collection block that collects return oil from the various circuits and leads it to the
thermostats and to the return oil filter.
D-Drain oil is a collection block that collects oil from the various circuits and leads directly to the
return oil filter.
L-Leakege oil is oil that goes directly to tank for minimum resistance in the circuits.

The filler pump is used to fill the system. There is a stop valve that prevents return oil from leaking
out through the filler pump. A level sensor (B143) detects the level of hydraulic oil in the tank. Should
this drop below a certain level, the diesel engine is switched off automatically. The sensor signal from
B143 goes via PLC input X36.

Temperature sensor (B362) sense the hydraulic oil temperature and the temperature will be shown
on the display. The engine will automatically stop if the hydraulic oil temperature exceeds 90ºC.
Note: This signal is connected directly to the EMS.

The drain cock is used to remove water of condensation or to empty the hydraulic oil tank.

Thermostats
By-pass valve

Oil cooler
T-Return
Check valves
Refill pump
D-Drain Ventilation
filter

Drain cock

Hydraulic oil tank Return- / drain oil filter

Test connections for the hydraulic circuits

1
2 5
3 6
4 7
8
Figure: Test connections for checking the hydraulic circuits.

Connect the test connections to the various outlets (see table below).

1. Hydraulic pump 1: Percussion, Drill feed, Rapid feed, Tramming, Positioning, RHS system
2. Hydraulic pump 2: Rotation
3. Hydraulic pump 3: DCT or Winch and positioning
4. Hydraulic pump 4: Cooler - hydraulics, compressor and diesel engine
5. Not used
6. Extractor unit *
7. Pilot pressure
8. Not used

Note
* Extra equipment
 Electrical system, general

Electrical system, general

General
ROC D5/D7/D9 is equipped with a 24 volt electrical system for monitoring and fault indication. The
electrical system is also used for controlling a number of hydraulic- and pneumatic valves. The
structure of the electrical system is illustrated in a block diagram.

Battery and charging

The power source for starting the engine is two 12 V/185 Ah batteries that are connected in series.
These are charged by a generator. The batteries are connected to the system via a manual battery
switch.

Main fuse
The power supply to the electric cabinet is fused by a 60 A main fuse (F300) and a 100 A main fuse
(F304).

Electric cabinet
The electrical cabinet (A1) contains 17 fuses, of which one automatic circuit breaker that limit the
intensity to the various sub-circuits, some auxiliary relays, a CCU and a PLC.

ECM
ECM (Electronic Control Module) is used for monitoring the engine’s functions and sensors. It
receives analogue and digital information from the engine and the rig. The ECM stops the diesel
engine automatically if a specific fault occurs. A specific fault is for example low oil pressure which
could cause major damage to the engine.

EMS
The ECM also indicates specific faults through indicator and warning lamps on the diesel panel and
EMS (Electonic Monitoring System) LED-display.

CCU
Winch control unit is a system for controlling the winch from the remote control box. The system
consists of two parts, the CCU (CAN Control Unit) and the remote control box.
There is a CAN serial communication between the CCU and the remote control box. The CCU is
located in the large electric cabinet (A1) and controls the hydraulic valves for tramming, positioning
(boom lift and boom swing) and the winch.
Electrical supply

Emergency stop

Start engine
Relay K5A

Relay Start ECM

K330

Pre- Ignition, start position

PLC, CCU heating
50
???? ???? Relay K4A Ci
rc
ui
t

Ignition position

25 ECM
Ci
rc
ui
t
The power source consists of 2 12V/185Ah
batteries connected in series. Before the main
switch is switched on there is power to the diesel
heater + timer.

When the main switch is switched on the Main switch ON

circuit 25 is activated which supplies power to
parts of the ECM, the EMS and working lights.

Ignition position activates circuit 50 which Timer. Diesel heater

supplies the diesel panel, preheating, the ECM,
the CCU and the PLC via K4A with power. Batteries

Note: The purpose of the signal from circuit 50

is only to close the relay contact to K4A.
In the start position the engine is started via
relay K5A.
Note: The electrical system's ground cables are
not isolated. This means that the system
consumes a small current even when no
functions are activated.

10
PLC
The PLC handles logic functions for rod-handling, rapid-feed stops, percussion, air flushing, DCT,
high/low speed on the diesel engine, hydraulic oil level, coolant level, air filter diesel / compressor and
for anti-jamming functions. The logic for the PLC is saved in an EEPROM (Program).

PLC Exp. unit

Impact led (H446) 3 (43) 3 (53)
Rapid/drill feed led (H452) 2 (42) 2 (52)
Drill mode magnets (Y179A,B) 1 (41) 1 (51) Magnet off drill lever (S453)
Rapid feed/threading relay (K178) Rapid feed/threading (S452)
0 (40)

Output Y Input
X
PLC Exp. unit
N189/H 7 (37)
N189/F 6 (36)
N189/E 5 (35)
4 (34)
Air filter clogged (H207) 3 (33)
Coolant level low (H215) 2 (32)
Hydr. oil level (H203) 1 (31)
Diesel engine enable (K330) 0 (30)

Output Y
Lamp test ECL-collection (K327)
Pump 3 positioning/winch (Y187)
Hydraulic jack out (K180)
Rpm diesel engine low rpm (K5B)
Flush air reduced (Y116)
Flush air full (Y115)
DCT Hatch open (Y253)
Impact hour counter (P108)
Impact on (Y101A)
Impact low (Y101B)
DCT filter 3 cleaning (Y251C)
DCT filter 2 cleaning (Y251B)
DCT filter 1 cleaning (Y251A)
Carousel rotation CW (Y303A)
Carousel rotation CCW (Y303B)
Arm to carousel (K11)
Brush greasing (K449)
Arm to drillcenter (K10)
Loose rodgrip (K7)
Open rodgrip (K6)
Sleeve retainer (Y309)
Rpd feed Stop backward (Y149)
Drillfeed backwards (Y109)
ECG Pump (Y107) ECG Relay
ECL Pump (Y106) ECL Relay
PLC Base unit
27 HQS drill stop
26 Startkey in ignition position (S139)
25 Shutdown
24 Air filter clogged engine/compressor (B360, B365)
23 Coolwater level (B361)
22 Hydraulic oil level normal (B143)
21 Low rpm diesel engine (S189)
Startkey in startposition (S139)
20 Drill feed backwards (B262)
17 High rpm dieselengine (S189)
16 Operator chair (B379)
15 Impact pressure high (S446B)
14 Impact pressure low (S446A)
13 Flush air full (S100)
12 Flush air reduced (S100)
11 Switch S130 in position drilling
23 Sleeve retainer (S182)
10 22 Take up rodstring (S113)
7 21 Open gripper (S111)
6 20 Carousel rotation counter clockwise (S111)
5 17 Carousel rotation clockwise (S111)
4 16 Arm to drillcenter (S111)
3 15 Arm to carousel (S111)
2 14
1 Rpd feed stop upper (B127)
13 Rpd feed stop uncoupling (B126)
0 Rpd feed stop lower (B122)
12
11 Adjust extended time (S459)
10 Adjust pause time (S458)
7 Carousel stop from the gripper (B183)
6 Carousel stop towards gripper (B182)
5 Adjust pulse time (S457)
4 Increase/decrease DCT time (S456)
3 Arm in carousel (B118)
2 Open DCT (S181)
1 Flow switsch (B142)
0 Rotation pressure (B134)

Output Y Input X
 Diesel engine

Diesel engine
The engine on the ROC D7 is a turbocharged, water cooled diesel engine from Caterpillar called C7.
The output at 2200 r/min is 168 kW.

Battery switch, off

Before the battery switch (S300) is switched on there are 24V to the cabin fan (activated with diesel
heater), the diesel heater and the timer via the fuses F201, F202 and F203. The generator G2 (B+) is
connected directly to the batteries.

Battery switch, on
When the battery switch (S300) is switched on there is 24 V to:
 ECM
 EMS
 Emergency stops and ignition
 Lighting and volt tester in A1 cabinet
 Electric fuel pump

OFF
ON

S300

S300

Ignition position
When the ignition key S139 is in the ignition position the contacts 30-15 and 30-75 are closed. The
ignition relays K4A, K4B and K4C are activated and the relay contacts are closed.

When the relay contact K4A is closed the ECM is supplied with voltage via fuse F12 under the
condition that relay K330 is activated by the PLC output Y30. PLC outputs are supplied with voltage
via F15 and remote control with winch via F14.

Conditions for activation of K330:

 Emergency stops S132A, S132B and S132C are not triggered
 Fuses F300, F1, F11, F12, F13 and F15 are not triggered
 Cooling water level sensor (B361) PLC/X37-On
 Hydraulic oil level sensor (B143) PLC/X36-On
 No shutdown signal from EMS PLC/X41-On
 Ignition key (S139) in ignition position PLC/X42-On
(contacts 30-15, 30-75 closed)
When the relay contacts K4B and K4C are closed the control panel in the cab is supplied with voltage,
which regulates working lights and seat heating amongst other things.

During the ignition phase, the fault indications lamps on the diesel panel are flashing for 2 seconds
while the ECM conducts a self test, PLC outputs Y27, Y31, Y32, Y33 are also activated for lamp test.
During this time the engine will not be able to start.

Start position
Conditions for activation of starter motor:
 Emergency stops S132A, S132B and S132C are not triggered
 Fuses F300, F1, F11, F12, F13 and F15 are not triggered
 S130 in tramming mode PLC/X24-Off
 Compressor switch (S180) off H180 off
 Ignition key (S139) in start position PLC/X34-On
(contacts 30-15, 30-50 closed)
Note: PLC/X34 can only be activated when the compressor switch (S180) is not activated, otherwise
the S180 contact will block the input signal to PLC/X34.

If the conditions above are fulfilled, PLC output Y24 is on which activates K5B which in turn pre-
controls relay K5A. When relay K5A closes, the starter motor (M1) is activated.

 PLC/Y24-On→ K5B relay→ K5A relay→ M1 is activated, i.e. engine is cranking.

The ECM is normally powered through PLC ouput operated by K330. When turning the starter motor
there will be voltage drop in the system which can temporarily cause the PLC to shut down. To ensure
power supply to the ECM, which is necessary for starting the engine, one of the contacts of K5B is
bridging the contatct of K330. This allows the ECM to be powered from the main electrical system.

During the starting phase, the ECM blocks any signal from the oil pressure switch for 15 seconds.
This is to prevent the engine from stopping if the start key is released as soon as the engine has started,
but the engine has not yet built up the correct oil pressure.

Control instrumentation
Following instruments monitors the diesel engine.

 Diesel fuel gauge P352

The fuel transducer B352 in the fuel tank sends a signal to the fuel gauge, proportional to the fuel
level. There is an adjusting screw on the backside of P352 for calibrating the true fuel level. The
lamp comes on when there are 75 litres remaining.

 Engine Monitoring System P354

VDO, tachometer with display. The EMS monitors and processes engine operating parameters
and diagnostic information. The unit has a digital LCD display which can read out the different
engine parameters monitored and display fault symbols when faults occur. Press button (S354) on
the VDO instrument in order to scroll between the menus on the display. Depress button (S354)
for 5 seconds to zero or acknowledge, and doubleclick in order to access Caterpillar's fault codes
for an alarm situation.

 Button for display S354

 Contrast adjustment knob R354

Fault indicators
The rig has monitoring functions to check that all data is relevant and correct. In the event of certain
faults, the diesel engine is turned off automatically. Other faults are merely indicated, which requires
the engine to be switched off and the fault rectified.

 Indicator lamp H207

Indicator lamp for clogged air filter for diesel
engine and compressor. The lamp comes on
when the filters are clogged.

 Indicator lamp H211

Alarm lamp for diesel engine monitoring. H180
The lamp comes on in the event of a fault code P352
from the diesel engine. H207
H212 P354
H211 H214
 Indicator lamp H212
Alarm lamp for diesel engine monitoring. H213 H215
The lamp comes on in the event of a falut code
H203 H382
from the diesel engine that switches off the
engine. H381
S354

 Indicator lamp H213 R354

Alarm lamp for rig monitoring. The lamp
comes on in the event of an alarm.

 Indicator lamp H214

Alarm lamp for rig monitoring. The lamp comes on in the event of an alarm that switches off the
engine.

 Indicator lamp H203

Signal lamp, low hydraulic oil level. The lamp comes on when the oil level is too low and the
engine is switched off.

 Indicator lamp H215

Indicator lamp for engine coolant level. The lamp comes on when the coolant level is too low.

 Indicator lamp H381

Indicator lamp for ECL collection. The lamp indicates inadequate pressure in the return line. It
comes on when drilling starts until the correct pressure is achieved.

 Indicator lamp H382

Indicator lamp for ECL collection. The lamp indicates excessive pressure in the return line. The
can be due to the return tank is being full.

Note: All faults should be checked thoroughly and rectified.

Engine speed
The engine speed can be de- or increased by flicking switch S189 up-
or downwards. By flicking the switch different times, this puts the
N189 connections (Din0-2) in different set of combinations, hence
providing the different engine revolutions, and this is controlled by
b c
the PLC output Y35-Y37 respectively.
a d

PLC can support 8 engine revolutions, and it can store 3 separate

engine speeds, one for tramming, one for rod handling and one for
drilling. The PLC remembers the engine speeds for rod handling and a
drilling even when the battery switch is turned off. In tramming mode
the system will always start on 1200 rpm. The speeds can all be set b
individually within the range specified below.

Condition for revolution between 1200-2200 tramming position c

Switch S130 NOT in drilling position

Condition for revolution between 1500-2200

Switch S130 in drilling position and reduced flushing air NOT activated (Y116/OFF)

Condition for revolution between 1800-2200

Switch S130 in drilling position and reduced flushing air activated (Y116/ON)

The engine starts on idling speed 1200 rpm, flicking the switch once upwards should increase the
speed to 1500 rpm, one more flick increases the speed to 1700 rpm, then the engine speed increases
with 100 rpm per flick upwards until it reaches the maximum speed of 2200 rpm. It is also possible to
hold the switch for several seconds in order to reach the maximum speed. To decrease the engine
speed from the idling speed, flick the switch once downwards takes down the speed step by step just
like upwards. When changing from tramming position to drilling, the engine speed automatically
increases to engine speed set for drilling and vice versa.

Engine revolution combinations from PLC Y35-Y37

PLC Y35 PLC Y36 PLC Y37 Engine speed RPM
/N189 /N189 /N189
Din2 Din1 Din0
Low Low Low 1200 RPM
Low Low High 1500 RPM
Low High High 1700 RPM
Low High Low 1800 RPM
High High Low 1900 RPM
High High High 2000 RPM
High Low High 2100 RPM
High Low Low 2200 RPM
 Compressor

Compressor
General
The built-in compressor is a single-stage compressor. Its normal working pressure is 10.5 bar with the
Caterpillar diesel engine.

Compressor unit
The compressor unit comprises two rotors: a drive rotor and a slide rotor mounted on rollers and ball
bearings. The drive rotor is driven by the diesel engine and transfers power to the slide rotor. The
rotors are lubricated with oil that is injected and mixed with the air. This increases efficiency since the
oil forms a seal between the rotor blade and the housing. The compressor unit is an Atlas Copco type
G106 screw compressor. The gear ration is 1.55.

Air flow
The intake air is drawn through the air filter and an over centre valve to the compressor unit. The over
centre valve also prevents oil returning into the system. The air is mixed with injected oil and goes
directly from the compressor to the air receiver. In the air receiver, the majority of the oil is separated
from the air/oil mixture using an oil separator. This oil is removed by a separator unit. The flow of
compressed air passes through a pressure valve to the drill rigs air system. The pressure valve prevents
the pressure in the air receiver dropping below the lowest working pressure for the compressor
(approx. 2.8 bar), even when the air outlet valves are open, to ensure the correct function of the oil
system.

Air Atmospheric Pressure

Air Regulating Pressure

Air Working Pressure

Air/Oil Mixture

Oil
Cooling and oil systems
Oil is used for lubrication, sealing and cooling. There is no oil pump with pressure provided by the air
pressure. The lower part of the air receiver acts as an oil tank. The air pressure means that the oil is
transported from the air receiver through the oil cooler and oil filter to the compressor unit. The
compressor unit has an oil platform at the bottom of the sleeve. The oil for rotor lubrication, cooling
and sealing is injected through a hole in this oil platform. The bearings are lubricated by oil injected
into the bearing housing. The air/oil mixture leaves the compressor unit and returns to the air receiver,
where the oil is separated from the air. The oil that is collected at the bottom of the oil separator
returns to the oil system through a cleaning line that has a flow limiter.
Note: A thermostat valve bypasses the oil cooler when the oil is below 70°C.

Air Atmospheric Pressure

Air Regulating Pressure

Air Working Pressure

Air/Oil Mixture

Oil

Regulator system
The compressor control system comprises a regulator valve. This valve controls the air volume
supplied by the compressor for air consumption whilst also keeping the working pressure within a
certain range. The control system also includes a load valve that is activated by a switch on the diesel
control panel. The load valve allows the diesel engine to warm up before engaging the compressor.

Instrument and fault indication

The pressure of the compressed air delivered from the compressor can be read from the pressure
gauge. The compressor also has a temperature indicator switch (B366), which automatically provides
indication and displays in plain text on the display that the temperature has risen. The system switches
off the diesel engine if the compressor temperature exceeds +120°C.
 Pumps and pilot pressure

Pumps and pilot pressure

Pump 1
Main pump 1 in the hydraulic system is an axial piston pump with variable displacement that delivers
oil to control the pilot pressure. The pump is pressure compensated, which means that the pressure is
constant irrespective of the flow, so long as the flow is below the maximum capacity of the pump (150
l/min). The pump pressure can be controlled using external pressure valves or the internal pressure
control valve (DR).

The pump delivers hydraulic power to the following functions:

 Percussion
 Feeding
 Feed positioning
 Boom positioning
 Tramming
 RHS system
During drilling, pump 1 is controlled by the actual output pressure.
During tramming, it is connected to an open circuit system with a flow distributor that distributes the
flow equally to left and right tramming motors.

Internal pressure valve

During tramming or positioning the internal
pressure control valve (DR) checks the pump
pressure. The DR valve also limits the max.
working pressure (250 bar) for the pump.

DR: Max. pressure LS: Standby pressure

External pressure valve
During drilling, the pump pressure is controlled
by two relief valves for high and low percussion.
These are connected to the pump control system.

Pump 1, pressure setting

Checking/determining standby pressure “LS”

1. Disconnect pilot hose P1X1 from the “LS” valve and plug the hose.
2. Connect the text gauge hose to outlet 1 on the test panel.
3. Start the engine and set the speed to 1500 rpm.
4. Set the drilling/tramming switch to drilling.
5. The pressure on the tester should be 20-25 bar.
6. Adjust the “LS” screw on the pump regulator if required.
7. Switch off the diesel engine and refit hose PIX 1 to the “LS” valve.

Checking/determining max. pump pressure ”DR”

1. Connect the tester hose to the connection on pump 1.
2. Start the engine and set the speed to 1500 rpm.
3. Set the drilling/tramming switch to drilling.
4. The pressure on the tester should be max. 250 bar.
5. Adjust the “DR” screw on the pump regulator if required.
Pump 2
Pump 2 delivers oil to the rock drill’s rotation motor. The maximum pump pressure for pump 2 is set
via the relief valve in the drill rotation circuit.

Pump 3 and 4
Pumps 3 and 4 are fitted as a double pump on the diesel engine’s power take off.

 Pump 3 delivers oil to the dust collector’s fan motor during drilling, or to the positioning/winch
circuit during tramming.
During drilling, the pressure of pump 3 can be set on a relief valve in the DCT valve block.
During tramming, the pressure of pump 3 is set constant at 210 bar.
Pump 3 is unloaded at engine start-up.
 Pump 4 drives the cooler motor for cooling the hydraulic oil, compressor oil as well as engine’s
intake air and cooling water. It also delivers oil to the track oscillation lock mechanism. Pump 4 is
a gear pump and is driven by the power take off on the side of the diesel engine. The pressure of
pump 4 cannot be adjusted but is controlled by the relief valve for the cooling fan. This is set to
160 bar for D5 and 220 bar for D7. This pump is permanently active.

Pilot pressure
The oil that controls the pilot pressure comes from pump 1 and pump 3. The oil is led to the main
drilling block/winch block from respective pump through a pressure reducing valve (set to 35 bar),
through a strainer and out to the pilot circuit.

The oil in the main drilling block is led through solenoid valve Y121, which guides the pilot pressure
either to the drilling or tramming circuit. To protect the pilot system against pressure surges, there is a
pressure limiting valve set to 50 bar. The oil is then led to the solenoid valve Y169, which shuts off the
pilot pressure supply to tramming and impact functions in the event of an emergency stop situation or
when the automatic drill-stop function is used.

P1 35 bar (pilot) → Drilling function, tramming function, tramming speed

→ control
P3 35 bar (pilot) → Winch function, positioning function
→
 Tramming

Tramming
Conditions
The tramming circuit includes functions for activating hydraulic functions that maintain the
tramming circuit and control the hydraulic power to the tramming motors.

Condition for Tramming:

- Drilling/Tramming switch S130 must be in a tramming position.

The pilot pressure is led through solenoid valve Y169, the function of which is to cut the pilot pressure
flow to tramming and impact functions in an emergency. When solenoid valve Y169 is activated, the
oil is led to valve Y121 which then leads the pilot pressure to either the drilling circuit or tramming
circuit. Y121 is controlled by switch S130 (see Fig. 1).

High and low speed can be selected. If low speed is selected, the pilot pressure is led through solenoid
valve Y121 and then to the directional valve in the main drilling block (see Fig. 2). If high speed is
activated, the pilot pressure is led through valve Y122 and on to the valve block for the tramming
motors (see Fig. 4).

Y169 Y122 Y121

Fig. 1: See full diagram for other parts

No.: 9840 0423 56 page 3(16)

The pilot pressure then activates the directional valve (see Fig. 2) in the main drilling block and
supplies the tramming block via the flow regulator with oil (see Fig. 3).

20
 Drill feed Rapid feed
Percussion Y120A Rotation

Directional valve
Fig. 2: See full diagram for other parts
No.: 9840 0423 56 page 2(16)

Tramming direction and speed is controlled by means of pilot pressure controlling the proportional
directional valves. There directional vavles are controlled by the tramming levers in the cabin
(see Fig. 3).

Tramming direction and speed can also be controlled using the tramming controls on the remote
control box (see chapter “Option”). These controls send a signal to the control valves (Y206, Y207)
for tramming forward or backward. The pilot pressure alters the position of the directional valves
proportionally. When the remote control box is activated, the tramming controls in the cab are
blocked.

Y206A

Y206B

Y207A

Y207B
Pilot pressure

Pump 1
Flow regulator

Fig. 3: See full diagram for other parts

No.: 9840 0423 56 page 4(16)
The valve block integrated in the tramming motors comprises a reversing valve, pilot brake valve and
a pilot sequence valve for releasing the tramming brake once the motor is pressurized. The pressure
regulator protects the brake cylinder from high pressure. For high-speed tramming, the valves are
activated by the pilot pressure as in the figure below.

Pilot pressure, high

speed
Brake
cylinder

Reversing
valve

Brake
valve

Reversing
valve

Sequence valve

Pressure
regulator

Fig. 4: See full diagram for other parts

No.: 9840 0423 56 page 4(16)

Tramming warning
When tramming backwards the pressure switches B174 and B175 gives a signal to the reversing
warning signal (H185, H186) / flash.

The warning signal can also be activated manually by using switch S186.

Hydraulic jack
The rear jack is controlled by switch S209, which energizes solenoid valves Y410A/B. Unlike the
other rigs, it is possible to tram with the rear jack while it is out.
 Positioning

Positioning
The positioning circuits (including track oscillation circuit) are primarily supplied with oil by pump 1.
Since the tramming circuit is also supplied with oil by pump 1, pump 3 has to be used for positioning
during tramming, even when the rig is standing still in tramming mode. Since pump 1 (250 bar) is
larger and works at a higher pressure than pump 3 (160 bar), positioning is more rapid and powerful
in drilling mode than during tramming. The flow from pump 1 is greater than from pump 3.

Boom and feed positioning

During tramming, pump 3 delivers oil to the positioning circuit. When the rig is in tramming mode,
solenoid valve Y187 is activated. This pressurizes the pump 3 circuit and connects it via a pressure
limiting valve to the positioning circuit (see Fig.). When the rig is not in tramming mode, the
positioning circuit is supplied with oil from pump 1, because pump 3 is then used for supplying the
DCT circuit.

The positioning cylinders are controlled directly from the positioning levers inside the cab. Lever
movement results in valve activation and the pump pressure can pass out to the cylinder.

Positioning can also be handled electrically from the remote control box (see chapter “Option”).

To boom & feed positioning

To track oscillation
Pump 3

See full diagram for other details

No.: 9840 0423 56 page 4(16)
Track oscillation
The track oscillation cylinders are controlled by directional valves Y419 and Y420 via the control
(S176, S177) in the cab. The oscillation cylinders are hydraulically linked by a solenoid valve Y473,
controlled by switch S445. This valve has two positions:

 Open position (floating)

When Y473 is activated, pilot pressure is delivered to the over centre valves. The ratio
between the over centre valves is 1/13, which means that 25 bar is needed for them to permit
oil flow to the cylinders connected in parallel. This position is used for tramming so that
unevennesses in the ground are compensated for between the two cylinders (see Fig.).
 Closed position (locked)
When valve Y473 is inactivated there is no flow between the cylinders (over centre valves are
closed). This valve position is used make the rig stable for drilling.

Over centre valves Over centre valves

Y473 Y473

Y410B Y410B

Y410A Y410A

Y419A Y419B Y420A Y420B Y419A Y419B Y420A Y420B

Figure: Open position Figure: Closed position

See full diagram for other details
No.: 9840 0423 56 page 4(16)

Over centre valves

Y473
 Oil pre-heating

Oil pre-heating
Pump 2 is used for pre-heating the hydraulic oil. Normal operating temperature of the hydraulic oil is
40°C. Before operating the drill rig the oil should be pre-heated to minimum operating temperature,
20°C.

When switch S130 is in the pre-heating position, solenoid valve Y120A in the main drill block is
activated. The oil must pass through a 2 mm restriction and create a pressure by the pressure limiting
valve (170 bar). The oil heats up. (See red marker in figure.)

Y120A

Shunt valve Pressure valves

Pressure limiting valve Directional valve
See full diagram for other details
No.: 9840 0423 56 page 2(16)